An Aerosolization Module for an Aerosol Generating System Having an Optimized Air Path Configuration

ABSTRACT

An aerosolization module for an aerosol generating device includes a bottom end, an opposite top end provided with a mouthpiece, a first air path for the aerosol flow, and a second air path configured to be in fluidic communication with a puff sensor. The first air path includes a first section in which dry air sucked into a first air inlet flows from top to bottom, and a second section in which the aerosol formed by vaporization of the vaporizable material in the dry air flows from bottom to top. The aerosolization device is located inside the module, and the first air inlet is located above the aerosolization device in a bottom to top direction. The mouthpiece is at the top end of the module, and the first air inlet is made through a bottom portion of the mouthpiece. The position of the first air inlet can thus be optimized.

FIELD OF THE INVENTION

The present invention relates to an aerosolization module for an aerosol generating system.

Aerosol generating systems allow vaporization of a product, generally a liquid, often called e-liquid or e-juice. The aerosol generating systems according to the invention are also commonly called vaporizers or electronic cigarettes.

More particularly, vaporization of the product is obtained, generally by heating, in an aerosolization module, also called atomizer. Aerosolization is the conversion of a substance, for example in liquid state or solid state, into particles small and light enough to be transported in the air.

Aerosol generating systems or e-cigarettes are thus portable devices comprising an electric heat source, included in an aerosolization module, that heats the product (e-liquid) to create an aerosol that the user inhales, and a battery to power the heat source.

BACKGROUND OF THE INVENTION

Several atomizer technologies and configurations are known for aerosol generating systems. Such atomizers usually include a reservoir filled with e-liquid known as “cartomizer” (which is the combination the words cartridge and atomizer), or “clearomizer” when the cartomizer’s reservoir has a clear or transparent side wall. They typically use an electric powered heating device or heater. A battery which is comprised in a battery module provides electric power to the heating device. The battery module and the aerosolization module can be formed as a one-piece system, but they are generally provided as separate modules.

The aerosolization module generally comprises the reservoir which is filled with vaporisable material to be aerosolized by the heater.

The term vaporizable material is used to designate any material that is vaporizable in air to form an aerosol. Vaporisation is generally obtained by a temperature increase up to the boiling point of the vaporization material, such as at a temperature up to 400° C., preferably up to 350° C. The vaporizable material may, for example, comprise or consist of an aerosol-generating liquid, gel, or wax or the like, or any combination of these.

They also generally comprise a puff sensor making it possible to determine when the user wishes the delivery of a puff by the system. The puff sensor generally comprises a pressure sensor, e.g. a pressure transducer. When a suction is applied on a mouthpiece of the aerosol generating system, a pressure drop generated by the suction and is transferred to the puff sensor by an air path. In response, a puff of aerosolized material is generated, typically by activation of the heater.

In most of the aerosol generating system, the same air path is used for the aerosol formed by vaporization of the vaporizable material, typically from the heater to the mouthpiece of the aerosol generating system, and for the communication of the pressure drop to the puff sensor.

However, this can disturb the operation of the sensor. Indeed, some of the aerosol can reach the puff sensor, and the vaporized liquid can condense there.

US 2019/150520 A1 discloses an aerosol delivery device including a mouthpiece end; an aerosol generation chamber in fluidic communication with the mouthpiece end via a primary air channel. The aerosol generation chamber comprises an aerosol source for generating an aerosol from a source material for inhalation by a user through the mouthpiece end during use; and a sensor for detecting when a user inhales on the mouthpiece end. The sensor is in fluidic communication with the mouthpiece end via a second air channel, distinct from the first air channel. The sensor is located further from the mouthpiece end than the aerosol source, and the secondary air channel bypasses the aerosol generation chamber.

However, this configuration can be optimized, as certain issues may arise depending on the configuration of the aerosol generating device. For example, the user’s fingers can obstruct the air inlet into the first air path or channel. Furthermore, the aerosolization module is generally adapted to be connected to a battery module to constitute an aerosol generating device. This connection might comprise the insertion of an end of the aerosolization module into a cavity or housing provided in the battery module, which can cause problems in designing the air intake in the module.

The present invention aims to provide an aerosolization module that has an optimized configuration, in particular with respect to the organization of the air paths within the module.

SUMMARY OF THE INVENTION

The present invention thus relates to an aerosolization module for an aerosol generating device comprising a reservoir adapted to contain a vaporizable material to be vaporized in air by an aerosolization device thereby forming an aerosol. The aerosolization module comprises a bottom end and an opposite top end which is provided with a mouthpiece.

The aerosolization module comprises :

-   a first air path comprising a first air inlet for air admission into     the first air path, and a first air outlet from which the aerosol     formed by vaporization of the vaporizable material exit; and -   a second air path distinct from the first air path, configured to be     in fluidic communication with a puff sensor.

The first air inlet is located between the bottom end and the opposite top end of the aerosolization module. The first air path comprises a first section in which dry air sucked into the first air inlet flows from top to bottom, and a second section in which the aerosol formed by vaporization of the vaporizable material in said dry air flows from bottom to top.

The aerosolization device is located inside the aerosolization module and the first air inlet is located above the aerosolization device in a bottom to top direction.

The aerosolization device is on the first air path, such that the air flowing in the first air path goes through the aerosolization device. In other words, the aerosolization device being interposed in the first air path, the air which circulates in the first air path passes from one side of the aerosolization device to the other. If the aerosolization device has a heater, the air circulates through or around it and becomes charged with vapor of vaporizable material.

The mouthpiece is at the top end of the aerosolization module, and the first air inlet is made through a bottom portion of the mouthpiece.

The module configuration provided by the invention allows for optimization of air flows in the module. Thanks to the air path for the aerosol being distinct from that of the puff sensor, the risk of the sensor measurement being disturbed by the vaporized product is eliminated. As the first air inlet is provided on a lateral wall of the aerosolization module, no complex interface with the battery module has to be provided. Furthermore, thanks to the configuration of the first air path, the position of the air inlet can be adapted to the general configuration of the aerosol generating device, in particular regarding its position in the axial direction (bottom to top direction) of the module between its bottom end and its top end. This makes it possible to avoid any risk of liquid leak from the first air inlet. This also makes it possible to avoid any risk of obstruction of the first air inlet when the aerosol generating device is used.

The first air inlet can be located at between 30% and 70% of the distance from the bottom end to the top end of the aerosolization module, and preferably at around 50% of the distance from the bottom end to the top end of the aerosolization module.

The bottom part of the aerosolization module can thus be inserted into a battery module, and/or be grasped by the user without risk of obstructing the first air inlet.

The first air outlet can be located on the mouthpiece of the aerosolization module.

The mouthpiece can be constituted by a cap which is fitted at the top end of the aerosolization module, and the first air inlet can be made through a bottom portion of the cap.

The second air path can issue from the aerosolization module on or into the mouthpiece.

These are different alternative configurations that can be envisioned in the invention. When the air paths are separate as far as their respective outlets, the puff sensor is completely isolated and protected from the aerosol. When the paths meet in the immediate vicinity of the mouthpiece, adequate sensor protection is obtained, and the ergonomics of the system are optimized.

The second air path can issue in the first air path in close proximity to the mouthpiece, so that the first air outlet and a second air outlet are common. The aerosolization device can comprise a heater, and the heater can be positioned on the first air path. The heater can be positioned on the second section of the first air path. The second section can comprise a central tube of the aerosolization module and, the heater can be installed at the bottom of the central tube.

The invention thus also makes it possible to obtain an optimized configuration of an aerosolization module comprising a heater. In particular, the heater can be positioned in the lower (bottom) part of the aerosolization module, and in particular under the reservoir of the module, without its air supply being problematic. This allows the heater to be reliably supplied under the effect of gravity with product (typically liquid) intended to be vaporized.

The puff sensor can be provided in the second air path. The puff sensor can be a pressure sensor. The second air path can have a second air inlet situated at an interface of the aerosolization module, said interface being configured for connection to a corresponding battery module.

The invention also relates to an aerosol generating device comprising a battery module and an aerosolization module as above described connected to the battery module. The second air path can have a fluid-tight connection with a space of the battery module enclosing the puff sensor. A seal can be provided at the second air inlet.

According to complementary or alternative embodiments of the invention, the puff sensor can be comprised in the aerosolization module or in the battery module. When a puff sensor is comprised in the battery module of the aerosol generating device, an air tight interface is provided between the second air inlet and the space of the battery module comprising the puff sensor.

BRIEF DESCRIPTION OF THE DRAWINGS

Other particularities and advantages of the invention will also emerge from the following description.

In the accompanying drawings, given by way of non-limiting examples:

FIG. 1 represents, in a schematic sectional view, an aerosolization module according to an embodiment of the invention;

FIG. 2 represents, in the same schematic sectional view as FIG. 1 , a first air path arranged in the aerosolization module of FIG. 1 ;

FIG. 3 represents, in the same schematic sectional view as FIG. 1 , a second air path arranged in the aerosolization module of FIG. 1 ;

FIG. 4 is a schematic sectional view of the aerosolization module of FIG. 1 , showing a detail of the present embodiment of the invention;

FIG. 5 represents, in a schematic three dimensional view, an aerosol generating system.

DETAILED DESCRIPTION

FIG. 1 represents an aerosolization module according to an embodiment of the invention.

The aerosolization module comprises a reservoir 1. The reservoir 1 defines an inner volume 2 that is adapted to contain a vaporizable material. The reservoir can be, by way of example, a one-piece plastic part, for example obtained by injection molding.

The vaporizable material can be in liquid form, in solid form, or in a semi liquid form (paste, gel, wax, etc.), or in a combination thereof.

Thus, the vaporizable material can be a liquid or a non-liquid material that can be transformed into a liquid to be aerosolized. If not already provided by the reservoir as a liquid, heat energy provided to the material contained in the reservoir induces its transformation into a liquid state. This may for example be the case if the reservoir 1 contains a vaporizable material consisting of or comprising a wax.

Vaporisation is obtained by heating the vaporizable material. To this end, the aerosolization module comprises, in the represented embodiment, an aerosolization device, namely a heater 3.

The heater 3 is configured to perform aerosolization of the vaporizable material.

The heater 3 comprises heating means such as a resistive element, such as a resistive wire 4 that is coiled in the represented embodiment.

The heater 3 is a so called “vertical heater”, installed vertically in the aerosolization module, i.e. such that the heater 3 extends in a bottom to top direction of the aerosolization module. The bottom to top or “axial” direction of the aerosolization module is thus defined between the bottom end 5 of the aerosolization module, which comprises an interface for connexion to a battery module as hereafter explained, and its top end 6 which comprises a mouthpiece 7.

The aerosolization module comprises electrical contacts 8 that are configured to provide the heater with electricity.

The electrical contacts 8 can be electrical plugs configured to mate with spring pin connectors, usually called “pogo pins™”. A spring pin connector is usually made up of two sliding cylinders constrained against each other by an internal spring. Other types of electrical contact can be used, for example electrical contacts configured to cooperate with plate spring contacts. In the represented embodiment, the electrical contacts are embedded, e.g. by insert molding, in the electrical contacts 8 of the aerosolization module. The bottom end 5 of the aerosolization module thus forms a power supply connecting end.

To allow the formation of an aerosol, the heater 3 must be provided with electricity via the electrical contacts 8, with vaporizable material from the reservoir, and with air.

The supply of vaporizable material to the heater is performed via holes 9, each hole 9 allowing fluidic communication between the inner volume 2 of the reservoir 1 and the heater 3. Several holes 9 can be distributed around the heater 3, to allow a good distribution around the heater of the product to be vaporized.

The heater 3 must be provided with air at one of its ends and be passed over by air along its length to be saturated with vaporisable product and thus to form an aerosol. As the mouthpiece 7 is situated at the top end of the aerosolization module, the heater 3 must be provided with air at its bottom end, to pass over the heater 3 to reach its top end.

More particularly, in the represented embodiment, the heater 4 is placed at the bottom of a central tube 10. The central tube 10 connects the mouthpiece 13 to the heater 4 where the aerosol is formed, and a first air path is thus formed in the aerosolization module.

This first air path 11 is provided for the flow of air to the heater 3 and the flow of aerosol (formed with this air) from the heater to the mouthpiece is described in detail with reference to FIG. 2 .

The first air path 11 has a first air inlet 12 for air admission.

The first air path 11 has a first air outlet 13, which is where the aerosol exits from the aerosolization module. The first air outlet 13 thus corresponds to the outlet of the central tube 10.

One of the aspect solved in the invention relates to the position of the first air inlet 12, in an aerosol generating device in which the first air path provided for the flow of air to the heater 3 and the flow of aerosol (formed with this air) from the heater to the mouthpiece is distinct form a second air path, hereafter described, the second air path being associated with a sensor used to determine when the user wishes the delivery of a puff by the system.

As the first air path is distinct from the second air path, the position of the first air inlet 12 is not constrained by the configuration of the second air path. However, other difficulties or constraints exist. Certain constraints can be understood by observing FIG. 5 .

FIG. 5 represents an aerosol generating system comprising an aerosolization module A, e.g. the aerosolization module of FIG. 1 , and a battery module B.

The battery module B is adapted to provide the aerosolization module and more particularly the heater with electricity. The battery module also generally includes a number of electronic components. These electronic components are used to control the aerosol generating system. They generally comprise a main printed circuit board assembly that carries a microprocessor. They also generally comprise the pressure sensor making it possible to determine when the user wishes the delivery of a puff by the system.

The battery module B has an upper cavity 14 in which the lower part 15 of the aerosolization module is received. When the lower part 15 is in place in the cavity 14, only the upper part 16 of the aerosolization module is apparent. The wall of the cavity 14 makes it difficult to provide the first air inlet 12 at the level of the heater 3, which is inside the cavity 14.

Furthermore, if the first air inlet 12 would be placed far from the mouthpiece 7, the risk of obstruction by the user’s finger would be high, resulting in poor ergonomics of the aerosol generating system.

In the invention, the first air inlet 12 is thus located between the bottom end 5 and the top end 6. It can be located on a lateral wall of the aerosolization module.

The first air inlet is advantageously located above the heater 3 (or other aerosolization device comprised in the aerosolization module). This avoids or limits the risk of leaks of vaporizable material in liquid form from the first air inlet. In the represented embodiment in which the lower portion 15 of the aerosolization module is inserted into a cavity of the battery module, the first air inlet 12 is situated above the lower portion, and more precisely at the bottom of the upper portion 16.

Such location is adequate, as the first air inlet 12 is not in front of a wall of the cavity 14, is far enough from the top end 6 of the aerosolization module not to be obstructed by the user’s lips, and is far enough from said top end 6 not to be obstructed by the user’s fingers when he or she manipulates the aerosol generating system. The first air inlet is thus advantageously at between 30% and 70% of the distance from the bottom end to the top end of the aerosolization module, and preferably at around 50% of the distance from the bottom end to the top end of the aerosolization module.

In the represented embodiment, the aerosolization module A comprises a cap 17. The cap 17 is fitted, e.g. by clipping, on the top end 6 of the aerosolization module and constitutes the mouthpiece 7. The cap 17 makes it possible to obtain a walls that are flush with each other, without a step, between the aerosolization module A and the battery module 2. The first air-path inlet 12 is made through a bottom portion of the cap 17.

To provide the heater 3 with air, the first air path thus comprises a first section 18 in which dry air flow sucked into the first air inlet flows from top to bottom, and a second section 19, namely the central tube 10, in which the aerosol formed by vaporization of the vaporizable material in said dry air flows from bottom to top. The first section 18 can be substantially arranged along or in a lateral wall of the reservoir 1. The air flow in the first air path is represented by dotted arrows in FIG. 2 .

FIG. 4 represents the second air path arranged in the aerosolization module of FIG. 1 . The second air-path is a fluidic path which connects the mouthpiece, where the user applies a suction to vape, and a pressure sensor adapted to detect the pressure drop caused by the suction and to command in response a switching on of heater 3.

The second air path 20 is distinct from the first air path, in that no flow of aerosol occurs in the second air path.

The second air path 20 has a second air outlet 21 where the suction has to be applied. The second air path can thus be situated on the mouthpiece 7. In this case, the second air outlet 21 is distinct form the first air outlet 13.

For a better design and better ergonomics, while the second air path 20 is distinct from the first air path 11, the second air outlet 13 and the second air outlet 21 can be common. In such case, the second air path issues into the first air path in close proximity to the mouthpiece.

According to alternative embodiments of the invention, the puff senor, e.g. the pressure sensor, is either comprised in the second air path (i.e; in the aerosolization module) or in the battery module.

It should be noted that the aerosolization module can be a consumable item of the aerosol generating device. It can also be designated by the term “cartridge”. Once the vaporizable material initially contained in the reservoir has been consumed, and the reservoir is empty, the aerosolization module is replaced by another aerosolization module with a full reservoir. The old module can be discarded, preferably for recycling. A change of aerosolization module can also be carried out, even before the reservoir is empty, in order to change the product to be vaped. This allows for example the user to choose the taste of the product consumed.

That is why the puff sensor is generally, and advantageously, comprised in the battery module B (such as in the represented embodiment). In this case, the second air path must be in fluidic, airtight, communication with the space of the battery module B enclosing the puff sensor. The second air inlet 22 is thus situated on the bottom end face of the aerosolization module, which forms an interface for connection (i.e. mechanical and electrical connection) with the battery module. A seal can be provided around the second air inlet 22 to ensure airtightness.

The air flow in the second air path 20 is represented by dotted arrows in FIG. 3 . The second air path can comprise a main channel 23 substantially arranged along or in a lateral wall of the reservoir 1.

In the represented embodiment, the second air inlet 22 is situated at the center of the bottom face of aerosolization module. FIG. 4 is a sectional view according the section plane C-C shown in FIG. 3 . FIG. 4 shows in particular that fluidic communication between the second air inlet 22 and the main channel 23 is provided by a curved channel 24 provided around an electrical contact 8 of the aerosolization module.

The aerosolization module provided in the invention, which comprises distinct air paths for the aerosol and for the puff detection, allows for an optimization of the air flows in the module. The risk of the sensor measurement being disturbed by the vaporized product is eliminated. Furthermore, as the first air inlet is provided on a lateral wall of the aerosolization module, no complex interface with the battery module has to be provided. Thanks to the configuration of the first air path, the position of the air inlet can be adapted to the general configuration of the aerosol generating device, in particular regarding its position in the axial direction (bottom to top direction) of the module between its bottom end and its top end.

References used for the figures A Aerosolization module B Battery module 1 Reservoir 2 Inner volume 3 Heater 4 Resistive wire 5 Bottom end 6 Top end 7 Mouthpiece 8 Electrical contacts 9 Hole 10 Central tube 11 First air path 12 First air inlet 13 First air outlet 14 Upper cavity 15 Lower part (of the aerosolization module) 16 Upper part 17 Cap (of the aerosolization module) 18 First section (of the first air path) 19 Second section (of the first air path) 20 Second air path 21 Second air outlet 22 Second air inlet 23 Main channel 24 Curved channel 

1. An aerosolization module for an aerosol generating device, the aerosolization module comprising: an aerosolization device, a reservoir adapted to contain a vaporizable material to be vaporized in air by the aerosolization device thereby forming an aerosol, a bottom end, an opposite top end which is provided with a mouthpiece, a first air path comprising a first air inlet for air admission into the first air path, and a first air outlet from which the aerosol formed by vaporization of the vaporizable material exits, a second air path, distinct from the first air path, configured to be in fluidic communication with a puff sensor, wherein the first air inlet is located between the bottom end and the opposite top end of the aerosolization module, and wherein the first air path comprises a first section in which dry air sucked into the first air inlet flows from top to bottom, and a second section in which the aerosol formed by vaporization of the vaporizable material in said dry air flows from bottom to top, wherein the aerosolization device is located inside the aerosolization module, and the first air inlet is located above the aerosolization device in a bottom to top direction, and wherein the mouthpiece is at the top end of the aerosolization module, and the first air inlet is made through a bottom portion of the mouthpiece.
 2. The aerosolization module according to claim 1, wherein the first air inlet is located at between 30% and 70% of the distance from the bottom end to the top end of the aerosolization module.
 3. The aerosolization module according to claim 1, wherein the first air outlet is located on the mouthpiece of the aerosolization module.
 4. The aerosolization module according to claim 1, wherein the mouthpiece is constituted by a cap which is fitted at the top end of the aerosolization module, and wherein the first air inlet is made through a bottom portion of the cap.
 5. The aerosolization module according to claim 1, wherein the second air path issues from the aerosolization module on or into the mouthpiece.
 6. The aerosolization module according to 1, wherein the second air path issues in the first air path in proximity to the, mouthpiece, so that the first air outlet and a second air outlet are common.
 7. The aerosolization module according to claim 1, wherein the aerosolization device comprises a heater, and wherein the heater is positioned on the first air path.
 8. The aerosolization module according to claim 7, wherein the heater is positioned on the second section of the first air path.
 9. The aerosolization module according to claim 8, wherein the second section comprises a central tube of the aerosolization module, and wherein the heater isinstalled at a bottom of the central tube.
 10. The aerosolization module according to claim 1, wherein the puff sensor is provided in the second air path.
 11. The aerosolization module according to claim 1, wherein the puff sensor is a pressure sensor.
 12. The aerosolization module according to claims 1, wherein the second air path has a second air inlet situated at an interface of the aerosolization module, said interface being configured for connection to a corresponding battery module.
 13. An aerosol generating device comprising a battery module and the aerosolization module according to claim 12 connected to the battery module wherein the second air path has a fluid-tight connection with a space of the battery module enclosing the puff sensor.
 14. The aerosol generating device according to claim 13, wherein a seal is provided at the second air inlet.
 15. The aerosolization module according to claim 1, wherein the first air inlet is located at 50% of a distance from the bottom end to the top end of the aerosolization module. 